Club Car 2009-20011 Electric Precedent Maintenance And Service Manual page 243

EXCEL SYSTEM TROUBLESHOOTING – MCOR
WARNING
• The key switch should be placed in the OFF position and left in the OFF position for the duration
of this test.
2. With the batteries connected, place Tow/Run switch in RUN. Using a multimeter set to 200 volts DC, place
red (+) probe on battery no. 1 positive post and place black (–) probe (with insulation-piercing probe) on the
purple/white wire at a point close to the three-pin connector at the MCOR. The reading should be approximately
48-50 volts (full battery voltage).
3. If reading is zero volts, check the purple/white wire continuity from the three-pin connector at the MCOR to the
16-pin connector at the speed controller. Check terminal positions in three-pin connector at the MCOR and the
16-pin connector. If all of the continuity readings are correct and the connectors are wired correctly, replace the
speed controller.
4. With multimeter set to 20 volts DC, place the black (–) probe on battery no. 4 (4 x 12-Volt battery set) or battery
no. 6 (6 x 8-Volt battery set) negative post and the red (+) probe (with insulation-piercing probe) on the white wire
at a point close to the three-pin connector at the MCOR. The reading should be approximately 4.65 volts.
5. If reading is zero volts, check the white wire continuity from the three-pin connector at the MCOR to the 16-pin
connector at the speed controller. Check terminal positions in three-pin connector at the MCOR and the 16-pin
connector. If all of the continuity readings are correct and the connectors are wired correctly, replace the
speed controller.
6. With multimeter set to 20 volts DC, place the black (–) probe on battery no. 4 (4 x 12-Volt battery set) or battery
no. 6 (6 x 8-Volt battery set) negative post and the red (+) probe (with insulation-piercing probe) on the no. 18
yellow wire at a point close to three-pin connector at the MCOR. The reading should be approximately 0.32 volts
with the pedal up. Slowly press the accelerator pedal and note the readings on the multimeter. As the pedal is
pressed, the reading should increase until it reaches 4.65 volts when the pedal is fully pressed.
7. If reading does not increase as the pedal is pressed, replace the MCOR.
8. If the reading is not approximately 4.60 volts with the pedal fully pressed, the vehicle will not operate at rated
top speed. Check the MCOR resistance.
8.1. Disconnect the batteries and discharge the controller. See Disconnecting the Batteries – Electric
Vehicles on page 1-3.
8.2. Disconnect the 16-pin connector at the speed controller.
8.3. Using a multimeter set for 20k ohms, connect the red (+) probe of the multimeter to the yellow wire at the
MCOR three-pin connector with an insulation piercing probe. Connect black (–) probe to the purple/white
wire with an insulation-piercing probe.
8.4. With the accelerator pedal fully up (not pressed), the multimeter should read approximately 1k ohms.
8.5. Slowly press the accelerator pedal while monitoring the multimeter. The resistance should rise as the
pedal is pressed. When the pedal is all the way to the floor, the multimeter should indicate between
5.67k ohms and 7.43k ohms.
8.6. Using a multimeter set for 20k ohms, connect the red (+) probe of the multimeter to the yellow wire at the
MCOR three-pin connector with an insulation piercing probe. Connect black (–) probe to the white wire with
an insulation-piercing probe.
8.7. With the accelerator pedal fully up (not pressed), the multimeter should indicate between 5.67k ohms
and 7.43k ohms.
8.8. Slowly press the accelerator pedal while monitoring the multimeter. The resistance should drop as the pedal
is pressed. When the pedal is all the way to the floor, the multimeter should indicate approximately 1k ohms.
8.9. If the MCOR does not operate as described, replace the MCOR. See MCOR Removal on page 17-8.
2009-2011 Electric Precedent Maintenance and Service Manual
14
Test Procedures
Page 14-17